Woven fabric and process for reinforced structural composites

摘要

A structural multi-layer fabric (A) is disclosed having a prescribed weave pattern and mesh which provides uniform flexibility and which can be used as a structural fabric or impregnated with a resin in a structural composite. The flexibility of the fabric facilitates conforming of the fabric to a desired shape. The rising and sinking warp yarns in the warp and weft directions facilitate effective impregnation by defining trough-like structures in the fabric, as well as enhancing the fabric flexibility. The fabric is characterized as having (N) layers, 2N basic warp yarns woven in a 2N yarn repeat, and (2N - 2) basic weft yarns woven in a (2N - 2) yarn repeat. In the illustrated embodiment, there are 10 basic weft yarn picks (60,62,64,66,68,70,72,74,76,78) and twelve basic warp yarns (34,36,38,40,42,44,46,48,50,52,54,56) woven in 6 layers (D,E,F,G,H,I). Warp yarns (B) and weft yarns (C) rise and sink in the fabric between outer face (30) and outer face (32). A first plurality of weft spaces (80) are defined in the fabric by rising pairs and sinking pairs of warp yarns (B). A first plurality of warp spaces (86) are defined in the fabric by rising pairs and sinking pairs of weft yarns (C). Two warp yarns (B) are disposed in the first plurality of weft spaces (80), and two weft yarns (C) are disposed in the first plurality of warp spaces (86). A single weft yarn (C) is disposed in the second plurality of warp spaces (88,90). IMAGE